Have you heard of a smart actuator? In recent years, artificial intelligence (AI) technology has advanced at a remarkable pace. Once limited to simple algorithmic functions, AI is now capable of understanding natural language, making complex judgments, and designing autonomous actions. This technological evolution is no longer confined to the software domain—it is now exerting a profound influence across the entire robotics industry.
One of the most significant shifts we are witnessing is the emergence of Physical AI—intelligent robots capable of performing physical tasks. While traditional AI has focused on analyzing data and making decisions, Physical AI goes a step further by manipulating objects, navigating environments, and executing tasks based on its own reasoning. This marks a departure from mere automation, pointing toward an era where AI not only thinks but moves with a physical presence.
This transformation is reshaping the functions, structures, and actuation systems of robots. In the past, industrial robots were designed primarily for repetitive tasks in controlled environments. Today, however, we are seeing a rise in intelligent robots that combine AI-driven decision-making with environmental awareness. From autonomous mobile robots in logistics to collaborative robots on factory floors and even service robots in households, robotics is expanding beyond factories to become a core technology that connects industry and everyday life.
As robots evolve to collaborate with humans and make autonomous decisions, they require a level of motion far more sophisticated than simple repetition. They must interpret complex commands in real time, move safely within dynamic environments, and carry out tasks with high precision. For such robots, the quality of their actuation systems becomes a critical factor in determining the performance, reliability, and safety of the entire system.
At the heart of this transformation lies the smart actuator.
What Is a Smart Actuators?
Traditional robotic systems required separate design and integration of motors, gear reducers, controllers, and sensors. However, a new approach is gaining widespread attention: a unified drive system that combines all these components into a single intelligent unit. This next-generation solution is known as the smart actuator. Especially well-suited for the era of Physical AI, smart actuators go beyond simply transferring force or position—they can sense their own status and respond accordingly.
Unlike conventional systems that demand complex integration of discrete parts, smart actuators consolidate motor, reducer, sensor, and control functionalities into one compact device. This integration not only maximizes spatial efficiency but also simplifies design complexity, significantly enhancing the overall performance of robotic systems.
The embedded sensors and controllers enable real-time monitoring of operational conditions without the need for external control units. Smart actuators can effectively manage position, speed, and torque control, making them highly suitable for advanced automation equipment and smart factory environments. They support seamless communication and control while collecting and analyzing various types of data, which allows for immediate detection of abnormalities and enhances system reliability.
How to Use Our Gear Reducer Design Service
1) Gear Reducer
A gear reducer is a mechanical component that reduces the high rotational speed of a motor while amplifying its torque. In simpler terms, it transforms fast but weak motion into slower and more powerful movement. Beyond just transferring mechanical power, the gear reducer plays a crucial role in determining how precisely a system can move.
The performance of a gear reducer depends heavily on the shape, structure, and machining quality of its internal gears. There are various types of gear mechanisms—cycloidal, planetary, bevel, worm gears—each designed for specific applications and conditions. Among these, the cycloidal gear reducer stands out for its exceptional durability and high torque output, making it especially well-suited for Physical AI applications where robust and responsive motion control is essential.
2) Motor
A motor is a device that converts electrical energy into rotational motion. From the small DC motors found in toy cars to the various types used in washing machines, fans, and robotic vacuum cleaners, motors are essential components that power both our everyday lives and industrial systems. There are many different types, including brushless DC (BLDC) motors, frameless rotors, and stepper motors.
The term frameless rotor may sound unfamiliar, so let’s break it down. While the basic working principle of all motors remains the same, a frameless rotor motor is one that does not include an external casing or fixed housing. Instead, only the core components—the stator (coil) and the rotor (magnet)—are provided, allowing users to integrate and assemble them directly into their own system designs.
This frameless configuration comes in two main types, depending on the rotor’s position: outer rotor and inner rotor.
In the outer rotor type, the stator (coil) is fixed at the center of the motor, while the rotor (magnet) wraps around it and rotates externally. In other words, the inner part is stationary while the outer part spins.
In the inner rotor type, the rotor (magnet) is located at the center shaft, surrounded by a stationary stator. This means the inner component rotates while the outer remains fixed.
Each configuration offers different performance characteristics.
The outer rotor design, with its larger rotational radius, is advantageous for generating high torque even at low speeds. In contrast, the inner rotor allows for higher rotational speeds (RPM) due to its compact radius, making it suitable for high-speed applications.
Thanks to their frameless architecture, these motors can be efficiently integrated into limited spaces and paired directly with gear reducers, enabling slimmer, more flexible designs. This makes them particularly well-suited for high-end robotic systems and equipment that demand precise and responsive actuation.
3) Encoder
An encoder is a sensor that measures how far, in which direction, and at what speed a robot or machine has moved—providing this information in real time. For instance, when a robotic arm needs to reach a specific position, the encoder continuously tracks its current location and sends that data to the controller. Based on this feedback, the controller decides whether to continue moving or to stop.
Encoders convert motion-related data—such as position, speed, and rotation direction—into electrical signals. These signals not only enable precise motion control but also integrate with AI systems, allowing robots to learn from movement patterns or analyze their own performance.
As with the gear reducer, the encoder is considered one of the most vital components in a smart actuator. Its ability to provide accurate, real-time feedback is essential for enabling smooth, intelligent motion—making it indispensable in modern robotics.
4) Brake
The brake is a critical safety component within a smart actuator, directly tied to operational security. While robots typically function without issue during normal operation, unexpected events—such as sudden power outages or emergency stops—can make it difficult to immediately halt motor rotation or hold a joint in place. In such cases, a robotic arm may drop its payload or lose balance, posing serious risks to nearby workers or equipment.
To prevent such scenarios, smart actuators are equipped with fail-safe brakes that automatically engage when power is cut. These brakes forcibly stop the motor or lock the joint in place, preventing accidental falls or collisions caused by external forces or gravity. They are especially essential in systems that support vertical loads or require fixed positioning.
To better understand this concept, consider the idea of a “blackout” in everyday life. When a person overexerts during physical activity and suddenly loses consciousness due to oxygen deficiency, their body collapses—often unpredictably and with significant force. Similarly, if a metal-structured robot suddenly shuts down and falls without restraint, it can cause unforeseen impacts or secondary accidents.
The brake serves as a safeguard against these events. Even in the absence of power, it ensures that the robot stops safely and holds its position, thereby protecting both human operators and surrounding equipment.
5) Driver
The driver serves as the smart actuator’s primary executor responsible for turning control commands into precise motor actions. Rather than simply sending power to the motor, the driver interprets instructions from the controller and delivers carefully modulated electrical signals that dictate when the motor should start or stop, in which direction it should rotate, at what speed, and how much torque it should generate.
The driver handles the full range of motor behavior: from smooth acceleration, steady cruising, to gradual deceleration. It also manages torque control by adjusting current levels, enabling fine-tuned rotation force. In essence, the driver acts as a highly skilled electrical conductor, orchestrating the motor’s every movement with precision.
This makes it clear that a smart actuator is far more than just a mechanical assembly. Each component—gear reducer, motor, encoder, brake, and driver—must work in seamless harmony. When these parts are organically integrated, they form an advanced motion solution that unites mechanical design and electronic control into a single, intelligent system.
Benefits of Adopting Smart Actuator Technology
The most significant advantage of smart actuator technology lies in the integration of key components—motor, gear reducer, controller, and sensor—into a single module. This unified architecture offers a range of practical benefits when designing robots and automation systems.
First and foremost, it greatly simplifies product design. Since there’s no need to position and assemble individual components separately, concerns about interference between parts or designing complex wiring paths are drastically reduced. This is particularly beneficial in compact environments, where implementing a drive system within tight spatial constraints becomes much more feasible. As a result, design flexibility increases, allowing for easier integration into compact systems such as small-scale robots or collaborative robots.
Simplified wiring and circuit layout also make maintenance far more efficient. In traditional systems, the more components you have, the more complex the wiring becomes—leading to a higher chance of errors. With a smart actuator, essential functions are consolidated into one module, which minimizes the need for external wiring. This not only results in a cleaner system layout but also enables quicker fault diagnosis, easier repairs, and smoother replacement procedures.
And from here, we’ve taken it a step further. We’ve committed to developing products that deliver even more powerful performance in an even more compact form—pushing the boundaries of what integrated motion systems can achieve.
Bonsystems Cycloidal Smart Actuator (BCSA)
The BCSA is a smart actuator developed by Bonsystems, incorporating our proprietary cycloidal gear structure.
Unlike conventional gear mechanisms, the cycloidal gear operates through a rolling motion rather than sliding, which significantly reduces wear and enhances durability. It also supports a wide range of reduction ratios without requiring changes to the product’s external shape or internal components. This capability allows for exceptional flexibility in design—an essential feature for next-generation robotic systems.
We recognized the potential of this technology early on. Among the many actuators currently available on the market, very few offer both a slim profile and high torque output. At Bonsystems, we aimed to solve this challenge by developing a new core actuation solution optimized for heavy-duty robotic systems.
To make this possible, we introduced a new idea: integrating a frameless outer rotor motor directly with the cycloidal gear reducer into a single structure. This fusion became the foundation for a thinner, more powerful, and design-friendly actuator configuration.
The result is the BCSA series—a line of smart actuators that deliver high torque despite their slim form factor. These actuators are ideal for equipment with space constraints or multi-axis robots that require compact, flexible configurations. With strong output and robust mechanical performance, BCSA offers an optimized solution for industrial robots and advanced automation systems where powerful motion and high load capacity are critical.
Want to Learn More About Our Products?
For any required materials or inquiries, please feel free to leave a message through the “Quotation Request” page. Whether you need specific technical documents or have questions about a particular application, you’re welcome to submit your request there.
Once we receive your inquiry, our team will promptly review it and respond with detailed answers along with relevant product materials. We’re committed to providing clear, accurate information to help you explore the full potential of our smart actuator solutions.
